Nilfisk-Advance Convertamatic 260B, Service Manual

Page 1: ...orm Number 56043021 Convertamatic 260B 32B 32BD 38BD SERVICE MANUAL Advance MODELS 56372450 260B 56395700 32B 56395710 32BD 56395720 38BD 56372460 260BHD 56395715 320BHD 56395725 380BHD Hydro Retriever 260BHD 320BHD 380BHD ...

Page 2: ...38 320 380 19 Brush Drive Motor Replacement 32 38 320 380 22 Brush Drive Motor Replacement 260 20 Brush Drive System Maintenance 14 Brush Drive System Troubleshooting 31 Caster Replacement 51 Differential Removal 32BD 38BD 320BHD 380BHD 49 Drive Belt Removal 32BD 38BD 320BHD 380BHD 45 Drive System Maintenance 45 Drive System Troubleshooting 32BD 38BD 320BHD 380BHD 52 Drive Wheel Removal 32BD 38BD ...

Page 3: ...Vacuum Motor Carbon Brush Inspection 32 38 320 380 35 Vacuum Motor Carbon Brush Inspection 260 33 Vacuum Motor Removal 32 38 320 380 38 Vacuum Motor Removal 260 36 Vacuum System Maintenance 32 Vacuum System Troubleshooting 44 Note All references to right left front or rear in this manual are as seen from the operator s stand point TABLE OF CONTENTS _________________________________________________...

Page 4: ..._______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ GENERAL SAFETY INSTRUCTIONS Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm...

Page 5: ...ry Use caution when moving the machine in below freezing temperature conditions Any water in the solution or recovery tanks or in the hose lines could freeze Do not leave the machine unattended without first turning the Main Switch OFF and applying the Parking Brake if applicable Turn the Main Switch OFF before changing the brushes __________________________________________________________________...

Page 6: ...w o batteries 702 lbs 318 kg w 220 AH batteries 733 lbs 332 kg w 244 AH batteries Battery Weight 65 lbs 30 kg each 220 AH battery 73 lbs 33 kg each 244 AH battery Battery Dimensions Height 10 63 inches 27 cm each 220 AH battery Width 7 06 inches 18 cm each 220 AH battery Length 10 25 inches 26 cm each 220 AH battery Height 11 5 inches 29 cm each 244 AH battery Width 7 06 inches 18 cm each 244 AH b...

Page 7: ...Recovery Tank Capacity 28 gal 106 litre Machine Weight 569 lbs 258 kg w o batteries 32B 627 lbs 284 kg w o batteries 32BD 320BHD 641 lbs 290 kg w o batteries 38BD 380BHD 1018 lbs 462 kg w batteries 32B 1076 lbs 488 kg w batteries 32BD 320BHD 1090 lbs 494 kg w batteries 38BD 380BHD Battery Weight 73 lbs 33 kg each 244 AH battery Battery Dimensions Height 11 5 inches 29 cm each 244 AH battery Width ...

Page 8: ...lean Vacuum Shut Off Float Clean Squeegee Charge Batteries Check Battery Water Level Lubrication Grease Lubrication Oil Service Vacuum Motor Lubricate these items every month with grease 1 2 pressure arm bearings 2 2 main wheel bearings 260 32B 3 4 differential bearings 2 intermediate shaft bearings 32BD 38BD 320BHD 380BHD 4 Caster swivel and wheel bearings if applicable Lubricate these items ever...

Page 9: ...32 38 320 380 6 The solution filter is flushed when ever the solution tank is drained through the drain hose 260 ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SOLUTION VALVE REPLACE...

Page 10: ...___________________________________________________________________________________________________________________________________________________________________________________________________________________________ SOLUTION VALVE REPLACEMENT 260 continued A E Front E D C B D 7 Solution Filter ...

Page 11: ...e solution valve 2 Remove the right side skirt and the right side brush 3 See Figure 2 Disconnect the 2 F solution hoses 4 Remove the 2 G screws holding the valve bracket to the chassis 5 Pull the solution valve down and disconnect solution cable H from the valve arm do not loose the bushing 6 Disconnect main solution hose I and remove the solution valve from the machine 7 Remove the old solution ...

Page 12: ..._______________________________________________________________________________________________________________________________________________________________________________________________________________________ SOLUTION VALVE REPLACEMENT 32 38 320 380 continued FIGURE 2 I Front G F H F 9 ...

Page 13: ...p the solution tank forward and remove the recovery tank from the machine 3 Remove the vacuum motor hose for easier access 4 See Figure 3 Disconnect solution cable J from the solution valve arm 5 Remove the solution cable from the chassis mount take note of its location in the mount 6 Remove the control handle panel 7 Remove the solution cable from the handle mount take note of its location in the...

Page 14: ...s Mount ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SOLUTION CABLE REPLACEMENT 260 continued 11 ...

Page 15: ...____________________________________________ SOLUTION CABLE REPLACEMENT 32 38 320 380 1 Drain the solution and recovery tanks 2 Remove the right side skirt and right side brush Lower the brush drive 3 See Figure 4 Disconnect the 2 K solution hoses 12 4 Remove the 2 L screws holding the valve bracket to the chassis 5 Pull the solution valve down and disconnect solution cable M from the valve arm do...

Page 16: ...__ Problem Not Enough Solution Flow To The Scrub Brushes 1 Kinked solution hoses 2 Solution valve cable needs adjustment 3 Plugged screen in the solution tank 32 38 320 380 4 Plugged solution filter 260 see figure 1 ________________________________________________________________________________________________________________________________________________________________________________________...

Page 17: ...ox and check the oil level The oil should be 1 1 2 inches 3 8 cm from the top of the gear box Use 140W gear lube only ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH DRIVE BELT ...

Page 18: ...________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH DRIVE BELT ADJUSTMENT 260 continued FIGURE 1 ...

Page 19: ...JUSTMENT 32 38 320 380 FIGURE 2 1 Drain the solution and recovery tanks and tip them to the sides of the machine 2 Open the front access door 3 See Figure 2 Loosen the 2 C bolts 4 Remove the belt guard 5 Turn the 2 large D bolts an equal amount of turns each to loosen or tighten the belt If you are removing the belt loosen the tension and remove the belt 6 There should be about 3 32 inch 2 mm of b...

Page 20: ..._____________________________________________________________________________________________________________________________________________________________ BRUSH DRIVE MOTOR CARBON BRUSH INSPECTION 260 1 Drain and remove the solution and recovery tanks and disconnect the batteries 2 See Figure 3 Remove access panel E from under the solution tank FIGURE 3 ...

Page 21: ...H DRIVE MOTOR CARBON BRUSH INSPECTION 260 continued FIGURE 4 3 See Figure 4 Remove the F brush covers from the brush drive motor 4 Remove one of the brushes from its holder 5 Measure the length of the brush If it is worn to a length of 3 8 inch 10 mm or less remove the brush motor see the BRUSH DRIVE MOTOR REPLACEMENT section of this chapter and replace all of the brushes If it is longer than 3 8 ...

Page 22: ...and tip them to the sides of the machine FIGURE 5 2 Disconnect the batteries 3 See Figure 5 Remove belt guard G 4 Remove large equalizer spring H 5 Remove bracket I 6 Remove the J brush covers from the brush drive motor 7 Remove one of the brushes from its holder 8 Measure the length of the brush If it is worn to a length of 3 8 inch 10 mm or less remove the brush motor see the BRUSH DRIVE MOTOR R...

Page 23: ...__________________________________________________________________________________________________________ BRUSH DRIVE MOTOR REPLACEMENT 260 1 Drain and remove the solution and recovery tanks and disconnect the batteries 2 See Figure 3 Remove access panel E from under the solution tank 3 Disconnect the brush drive motor wires take note of their location for reassembly 4 See Figure 6 Remove large e...

Page 24: ...brush drive motor 8 Reassemble in reverse order and test for proper operation FIGURE 6 ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRUSH DRIVE MOTOR REPLACEMENT 260 continued ...

Page 25: ...________________________________________________________________________________________________________ BRUSH DRIVE MOTOR REPLACEMENT 32 38 320 380 1 Drain the solution and recovery tanks and tip them to the sides of the machine 2 Disconnect the batteries and open the front access door 3 See Figure 7 Remove panel O 4 Disconnect the brush drive motor wires take note of their location for reassembl...

Page 26: ...________________________________ BRUSH DRIVE MOTOR REPLACEMENT 32 38 320 380 continued FIGURE 8 5 See Figure 8 Remove the 2 P bolts and remove the belt guard 6 Remove large equalizer spring Q 7 Remove bracket R 8 Turn the 2 large S bolts to loosen the belt tension and remove the belt 9 Remove bolt T and remove the brush drive motor from the machine 10 Remove the 4 U bolts and nuts and remove the m...

Page 27: ...s springs and washers 6 Disconnect the solution hoses from the X tubes 7 Remove the Y bolts and lift the pressure arm assemblies out of the machine 8 Remove the Z nuts 9 Use blocks of wood to support the brush holder OO and drive the pressure arm shaft PP out of the brush holder and pressure arm QQ Note Hold a brass drift against the pressure arm shaft and hammer on the drift Hammering directly on...

Page 28: ...______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PRESSURE ARM BEARING REPLACEMENT 260 continued ...

Page 29: ...2 CC bolts springs and washers 7 Disconnect the solution hoses from the DD tubes 8 Remove the EE bolts and lift the pressure arm assemblies out of the machine 9 Remove the FF nuts 10 Use blocks of wood to support the brush holder RR and drive the pressure arm shaft SS out of the brush holder and pressure arm TT Note Hold a brass drift against the pressure arm shaft and hammer on the drift Hammerin...

Page 30: ...________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PRESSURE ARM BEARING REPLACEMENT 32 38 320 380 continued FIGURE 10 ...

Page 31: ...alling the pad holders on the machine 2 Push the control handle lock down to hold the handle in the neutral position and lower the brush drive to the floor 3 See Figure 11 Loosen lock nut HH 4 Turn the main power switch ON and start the brush drive motor The machine should not move forward or reverse with the handle locked in the neutral position 5 If it does turn propelling adjustment shaft II to...

Page 32: ...____________________ PROPELLING LINKAGE ADJUSTMENT 32 38 320 380 1 Put the brushes or pad holders on the machine Make sure that they are the proper size and type for the machine If pad holders are being used install proper size pads before installing the pad holders on the machine 2 See Figure 12 Disconnect spring JJ take note of its location for reassembly this step is for drive models only 3 Low...

Page 33: ... Test run the machine to make sure it does not move in any direction when locked in neutral When testing move the machine around to different locations to make sure an uneven floor surface is not causing it to move 9 See the TROUBLESHOOTING section of this chapter if the machine does not propel properly FIGURE 13 _____________________________________________________________________________________...

Page 34: ..._____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem Squealing Noise When Brushes Are Lowered 1 Brush drive belt needs adjustment _____________________________________________________________________________...

Page 35: ...squeegee tool 2 Replace the squeegee blades if they are nicked or torn 3 If the edge of the squeegee blade is worn to a radius turn it around or over so a new edge faces forward 4 Inspect the squeegee hose rinse any built up dirt from the hose Replace the hose if it is kinked or damaged 5 Clean the float ball cage 6 Check the recovery tank cover gasket to make sure it seals 7 Check the drain hose ...

Page 36: ...__________________________________________________________________________________________________________________________________________________________ VACUUM MOTOR CARBON BRUSH INSPECTION 260 1 Drain the solution and recovery tanks and remove them from the machine 2 Disconnect the batteries 3 See Figure 1 Remove access panel A 33 FIGURE 1 A Front ...

Page 37: ...the brush Replace both brushes if it is 3 8 inch 10 mm or shorter 8 Reassemble in reverse order and test for proper operation ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ VACUUM MO...

Page 38: ...ecovery tanks and tip them to the sides of the machine 2 Disconnect the batteries and open the front access door 3 Remove the large equalizer spring take note of which hole it is hooked in before removing 4 See Figure 3 Remove access panel C FIGURE 3 35 5 Remove plastic cover D from the end of one of the vacuum motors 6 Remove one of the brush holders and remove the carbon brush from the motor 7 M...

Page 39: ..._________________________________________________________________________________________________________________________________________ VACUUM MOTOR REMOVAL 260 1 Drain the solution and recovery tanks and remove them from the machine 2 Disconnect the batteries 3 See Figure 4 Remove access panel E 4 Unplug the vacuum motor from the wiring harness 36 Front E FIGURE 4 ...

Page 40: ... and test for proper operation ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ VACUUM MOTOR REMOVAL 260 continued 37 FIGURE 5 Front F F F ...

Page 41: ...AL 32 38 320 380 1 Drain the solution and recovery tanks and tip them to the sides of the machine 2 Disconnect the batteries and open the front access door 3 Remove the large equalizer spring take note of which hole it is hooked in before removing 4 See Figure 6 Remove access panel G FIGURE 6 G H Front 5 Disconnect the vacuum motor s that you are removing from the wiring harness 6 Remove the 3 H s...

Page 42: ...lades if they are cut nicked or wavy 3 Put the squeegee back on the machine and put the squeegee lever in the down position 4 See Figure 7 Turn the I screws to set the squeegee angle so that the front and rear blades touch the floor equally Alternate between the screws making small adjustments one turn or less at each one 39 5 If the front blade is off the floor loosen the top screws and tighten t...

Page 43: ... blade is worn to a radius turn it around or over so that a new edge is facing forward 3 Put the squeegee back on the machine and put the squeegee lever in the down position 4 See Figure 8 Turn the J screws to set the squeegee angle so that the entire length of the wiping blade sits flat on the floor Alternate between the screws making small adjustments one turn or less at each one FIGURE 8 5 If t...

Page 44: ..._________________________________________________________________________________________________________________________________________________________________ SQUEEGEE BLADE REPLACEMENT STRAIGHT 1 To disassemble the squeegee cartridge remove the 2 small K screws and 2 large L screws see Figure 9 41 FIGURE 9 K K L L O M N Wood Support Blocks ...

Page 45: ... 2 large L screws to draw all parts securely together 8 Remove one L screw and install a small K screw in its place then repeat this step with the other L screw _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________...

Page 46: ...__________________ SQUEEGEE BLADE REPLACEMENT CURVED 1 Remove the squeegee tool assembly and disassemble it 2 Discard the worn blade s and thoroughly wash the remaining parts 3 Install the new blade s and reassemble as shown in Figure 11 4 Make sure that the screws or nuts are not so tight that the blades are wavy or bent out of shape 5 Reinstall the squeegee on the machine and test for proper ope...

Page 47: ..._______________________________________________________________________________________________________________________________________________________ Problem Water In Vacuum Motor 1 Operator using a high sudsing detergent 2 Drain hose plug not sealing 3 Vacuum shut off float not closing ______________________________________________________________________________________________________________...

Page 48: ...shaft bearings and the caster swivel and wheel bearings once per month 2 Lubricate the drive chain every 3 months ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DRIVE BELT REMOVAL 32...

Page 49: ...shes lower the brush drive assembly open the left splash guard and front access door 6 Remove bolt D and lower the idler pulley assembly to the floor Be careful not to loose the bushing and washers around bolt D 7 Remove bracket E from the top of the gear box 8 Remove bolt F pull belt guard G toward the rear and work belt H off of lower pulley I 9 Work the belt off of idler pulley J off of upper p...

Page 50: ... of the wheels 3 Reassemble in reverse order and test for proper operation ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MAIN WHEEL REMOVAL 260 1 Drain and remove the solution and r...

Page 51: ...on ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MAIN WHEEL REMOVAL 32B 1 Drain the solution and recovery tanks remove all of the battery cables remove the batteries and tip the mac...

Page 52: ..._________________________________ DIFFERENTIAL REMOVAL 32BD 38BD 320BHD 380BHD 1 Drain the solution and recovery tanks remove all of the battery cables remove the batteries and tip the machine on its left side 2 Remove the master link from the drive chain and remove the chain from the machine 3 See Figure 4 Remove the P bolts holding squeegee centering assembly Q in place and remove the centering ...

Page 53: ... file or a wire brush and loosen the Z set screws see Figure 5 ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DIFFERENTIAL REMOVAL 32BD 38BD 320BHD 380BHD continued 7 Collar AA must ...

Page 54: ...________________________________________________________________________________________________________________________________________________________________________________________ CASTER REPLACEMENT The caster wheel is located on the back of the 260 and on the front of the 32 38 320 380 The bearings in the swivel portion of the caster seldom fail The bearings in the caster wheel are usually d...

Page 55: ...20BHD 380BHD Before troubleshooting the transport drive system make sure the brake is OFF ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Problem No Wheel Drive But Brush Motor Runs 1...

Page 56: ..._______________________________________________ BATTERY MAINTENANCE Proper maintenance of electric vehicle batteries can greatly extend their life There are 3 simple rules for good battery maintenance Maintain Proper Electrolyte Level Use distilled water in batteries whenever possible If batteries are discharged add just enough water to cover the plates in each cell If batteries are fully charged ...

Page 57: ... or more cell that is putting out less voltage than the other cells Note Always charge batteries before testing There are 2 ways to find a dead cell Use a hydrometer to check the specific gravity or state of charge of the fluid in each cell A dead cell is one that reads 50 points or more lower than the other cells Use a volt meter to check the voltage of each battery with the brush and vac motors ...

Page 58: ...Nilfisk Advance Inc 14600 21st Avenue North Plymouth MN 55447 3408 www nilfisk advance com Phone 800 989 2235 Fax 800 989 6566 2001 Nilfisk Advance Inc Plymouth MN 55447 3408 Printed in the U S A ...